BACKGROUND OF THE INVENTIONThe present invention relates generally to the field of tandem axle assemblies and, in particular, to an interaxle differential mechanism which, in accordance with the present invention, is provided with a lubricant sump for providing lubricating oil to the differential mechanism during both initial start-up and normal running conditions. The present invention also concerns a unique gear structure which is one component of the interaxle differential. The gear is disk shaped and is provided with integrally formed internal clutch and side gear teeth.
Interaxle differential mechanisms are typically provided in tandem axle assemblies for dividing power from a single drive shaft to two separate axle assemblies. Examples of conventional interaxle differential mechanisms are disclosed in U.S. Pat. Nos. 3,441,106 to Taylor et al. and 2,033,246 to Keese. While tandem axle assemblies having interaxle differential mechanisms have been used for a long time and many various designs have been proposed, there is a continuing effort being made to improve the construction of the interaxle differential in order to reduce its weight and improve its durability and operating characteristics.
For example, the above mentioned Taylor et al patent discloses an interaxle differential construction wherein a side gear of the differential includes external formed side teeth on one side, externally formed clutch teeth on the opposite side engageable with a locking mechanism, and a radial periphery provided with external teeth for transmitting power to one of the two axle differentials. It has been found that this type of structure reduces the number of components in the assembly.
Also, various systems have been proposed for providing lubrication to an interaxle differential, which is typically located in an upper portion of a housing which also encloses one of the two axle differential mechanisms. In this type of arrangement, the interaxle differential is not immersed in the main oil sump, and is typically lubricated by either an auxiliary oil pump or by oil thrown toward the differential by a rotating ring gear. However, such systems generally do not provide sufficient lubrication during initial start up conditions, resulting in undesirable wear of the associated components.
The above mentioned patent to Keese has proposed the use of a separate retaining plate which cooperates with the interaxle differential housing to define an area for retaining a portion of the oil supplied to the interaxle differential mechanism.
SUMMARY OF THE INVENTIONThe present invention concerns a unique structure for providing a lubricant sump for a lower portion of an inter axle differential of a tandem axle assembly. Such a lubricant sump has been found to provide a sufficient supply of lubricating oil to the interaxle differential during both initial start-up and normal running conditions to prevent undesirable wear of these components.
More specifically, the interaxle differential assembly is rotatably supported within an associated housing. The housing includes means for at least partially enclosing at least a lower portion of the differential mechanism. An apertured cup member is affixed to the housing and is located between one of the side gears of the interaxle differential and the associated pinion gear carrier. An input shaft secured to the pinion gear carrier extends through the cup member. An annular seal means is positioned between the apertured cup member and the one side gear such that the housing, the apertured cup member, the annular seal means, and the side gear cooperate to define a lubricant sump for the interaxle differential mechanism.
In the preferred embodiment of the invention, the side gear of the interaxle differential which cooperates to define the lubricant sump is a disk-shaped gear means having a first generally planar surface which faces the differential pinion gear carrier. A plurality of side gear teeth are internally formed in the planar surface to define the associated side gear. Also, the annular seal means is positioned in a groove formed in the first planar surface, with the seal means including a sealing element for sealingly contacting an annular sealing surface on the apertured cup member.
Also, in accordance with the present invention, the disk-shaped gear means includes a second opposite planar surface having a plurality of internally formed clutch teeth for engagement with clutch teeth of an associated locking means. The locking means functions to lock the two side gears of the interaxle differential mechanism together, such that power is transmitted directly to each axle differential. Further, the disk-shaped gear means is provided with a radial periphery defining a plurality of gear teeth adapted to engage and drive an output gear connected to an output shaft coupled to drive one of the axial differentials. It has been found that such a gear construction, simplifies the assembly of the differential unit, while also reducing the overall axial length of the unit.
The above, as well as other advantages of the present invention, will become readily apparent to one skilled in the art from reading the following detailed description of the preferred embodiment of the invention in conjunction with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGSFIG. 1 is a top plan of a tandem axle assembly which incorporates the features of the present invention;
FIG. 2 is a sectional view of the rear differential of the tandem axle assembly of FIG. 1, taken along the line 2--2 in FIG. 3;
FIG. 3 is a sectional view of the rear differential of FIG. 2 taken along thelines 3--3 in FIGS. 1 and 2;
FIG. 4 is a side elevational view taken along line 4--4 in FIG. 2, and showing the bearing retainer locking means utilized with the invention;
FIG. 5 is a sectional view of the interaxle front differential of FIG. 1, taken along the lines 5--5 in FIGS. 1 and 6;
FIG. 6 is a sectional view of the interaxle differential assembly of FIG. 5, taken along the line 6--6 in FIG. 5; and
FIG. 7 is a sectional end view of an interaxle differential assembly according to the invention taken along the line 7--7 in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTTurning first to FIG. 1, there is shown a tandemrear axle assembly 20 including an interaxlefront differential 22 driven through adrive shaft 24 and driving anintermediate drive shaft 26, which in turn drives arear differential 28. Since bothdifferentials 22 and 28 are adapted to drive rear wheels, thedifferential 22 is sometimes referred to as a "front-rear" differential, while thedifferential 28 is referred to as a "rear-rear" differential. It will be appreciated that the features of the invention may be applied to various types of differentials, including a two-speed differential mechanisms and a single axle differential mechanism.
As illustrated, the interaxlefront differential 22 is driven at itsinput yoke 30 by a conventional universal joint assembly, and drives theintermediate drive shaft 26 through anoutput yoke 34, connected to the front end of theintermediate drive shaft 26 by a universal joint assembly. The rear end of thedrive shaft 26 is coupled to drive therear differential 28 at aninput yoke 38 by a universal joint assembly. Thedifferentials 22 and 28 includeouter housings 42 and 44 having integralaxle housing portions 46 and 48 which in turn support the respectiverear wheel assemblies 54 and 56.
Turning now to FIG. 2, there is shown a top sectional view of the singlerear differential 28. As illustrated, theinput yoke 38 is fastened to the forward end of aninput pinion shaft 58 by a fastening means 59, shown as a nut and washer fastened to a threaded stud integral with theshaft 58. The rear end of theinput shaft 58 carries aninput pinion gear 60. Theshaft 58 is rotatably supported within adifferential housing 68 by a pair of opposed tapered roller bearingassemblies 72 and 74. The roller bearing assemblies have respectiveouter races 64 and 66 which are fixed with respect to thedifferential housing 68. The bearing assemblies haveinner races 69 and 70 which are fixed with respect to theshaft 58. A conventional annular seal means 76 is provided at the forward end of theinput shaft 58 between theyoke 38 and thehousing 68.
In a conventional fashion, theinput pinion gear 60 drives aring gear 78 which is fastened to adifferential gear case 80 by a plurality ofbolts 82. Thedifferential gear case 80 defines a chamber for receiving a pair of spaced apartdifferential pinion gears 84 and 86. Thepinion gears 84 and 86 are rotatably supported on ashaft 88 secured to thecase 80 bypins 90 and 92 which are located inbores 94 and 96, and pass through corresponding apertures in the ends of theshaft 88.
A pair ofside gears 100 and 102 mate withpinion gears 84 and 86 and are respectively splined to the inner ends ofaxle shafts 104 and 106 (shown in phantom) atsplined portions 108 and 110. Thepinion gears 84 and 86 have respectivespherical faces 116 and 118 which are received in corresponding spherical seats formed in thecase 80.Spherical thrust washers 120 and 122 are positioned between the spherical pinion gear faces 116 and 118 and the respective spherical seats. Thespherical faces 116 and 118 and the associated spherical seats are defined by spherical surfaces of radius R1 having a generating center point (Pt.C) lying on the axis of rotation of thepinion gears 84 and 86.
To reduce the width and weight of the differential mechanism, theside gears 100 and 102 are provided withconical faces 124 and 126, which are symmetrical, and have an axis of generation aligned with the axis of rotation of thegears 100 and 102. These conical faces are received in respective conical seating areas formed in thecase 80.Conical thrust washers 132 and 134 are positioned between the conical gear faces 124 and 126 and the respective conical seating areas. In order to reduce the overall axial width of the differential, the conical seats are preferrably formed to such that the distance R2 (shown in FIG. 2) from point C the portions of the conical surfaces adjacent thesplined portions 108 and 110 is less than the radius R1. This results in the maximum spacing between the back surfaces of the side gears along the axis of rotation of the side gears being less than the maximum spacing between the back surfaces of the pinion gears along the axis of rotation of the pinion gears. However, it will be appreciated that, in some instances, it may be desirable to have the radius R.sub. 1 be less than the radius R2.
Thedifferential gear case 80 is rotatably supported within thedifferential housing 68 by a pair of taperedroller bearings 136 and 138. Thebearings 136 and 138 have respectiveouter races 140 and 141 which are press fit withinannular recesses 142 and 143 formed in the ends of thecase 80, andinner races 144 and 145 which are press fit overinner hub portions 146 and 147 of externally threadedbearing retainers 148 and 150. Theinner races 144 and 145 carry bearingroller cages 152 and 154 respectively.
Turning now to FIGS. 2 and 4, there is shown a means for securing the bearingretainers 148 and 150 in a selected adjusted position. As illustrated, thedifferential housing 68 defines axially aligned spaced apart threadedbores 156 and 157 for the reception of the bearingretainers 148 and 150. Thebores 156 and 157 are formed of a diameter D1 which is greater than the outermost diameter of the bearingroller cages 152 and 154. As will be discussed below, this greatly facilitates the assembly of the differential mechanism by enabling theretainers 148 and 150 to be inserted in the respective threaded bores with the associated inner races and bearing cages mounted thereon.
As shown in FIG. 4, thehousing 68 is split at aline 158, which terminates at the threadedbore 157. Thehousing 68 is provided withprojections 160 and 162 defining thesplit line 158. Theprojections 160 and 162 are provided with colinear apertures for retaining aclamping bolt 166, which is fastened with anut 168. By adjusting theclamping bolt 166, the threadedbore 157 may be tightened around the threadedbearing retainer 150 in a preliminary manner to prevent the unintended movement of the bearingretainer 150 as thebearing 138 is being adjusted. As a final step after thebearing 138 has been adjusted, thebolt 166 can be tightened to close thesplit line 158.
In addition, the bearingretainer 150 has an annular toothed or castellated portion defining a plurality of outwardly extendingteeth 172. A fingered locking plate 174 (shown in FIG. 4) engages at least two of theteeth 172 and is rigidly affixed to thehousing 68 by means of abolt 176 engaging a corresponding threaded bore in thehousing 68. In this manner, the bearingretainer 150 may be adjusted in a stepwise manner under an appropriate amount of drag caused by the adjustment of thebolt 166 and, when appropriate adjustment is achieved, the fingered lockingplate 174 is applied and fixed in position and theclamping bolt 166 is further tightened, yielding two separate and cooperating means for keeping the bearing retainer from becoming misadjusted during a long-extended service life. It will be appreciated that, in some instances, either theclamping bolt 166 or thelocking plate 174 can be eliminated, and only a single means can be used to lock the bearing retainers. Theother bearing retainer 148 can be provided with a similar adjusting and locking structure.
The method of assembling thedifferential gear case 80 and thebearings 136 and 138 is greatly facilitated by the structure of the present invention. Initially, theinner races 144 and 145 having the associatedroller cages 152 and 154 mounted thereon are pressed onto the reduceddiameter hub portions 146 and 147 of therespective bearing retainers 148 and 150. Therespective bearing rollers 152 and 154 are maintained on the associated inner races as assemblies by conventional bearing cage members. Then, theouter races 140 and 141 are pressed into theannular recesses 142 and 143 in the ends of thedifferential gear case 80.
Next, thedifferential case 80 is inserted into the open rear end of thecarrier housing 68, with thering gear 78 engaging theinput pinion gear 60. As illustrated in FIG. 2, the overall width of thedifferential case 80 is less than the width W of the opening provided in the rear end of thehousing 68. Following this, the inner ends of the bearingretainers 148 and 150 having the bearingcages 152 and 154 mounted thereon are passed through the respective threadedbores 156 and 157 and seated within their respectiveouter races 140 and 141 as the bearing retainer means 148 and 150 are screwed into the threaded bores 156 and 157.
The adjustment of the bearingretainers 148 and 150 centers thecase 80, and determines the proper engagement of thering gear 78 and theinput pinion gear 60, as well as establishing the proper preload on thebearings 136 and 138. After the proper engagement of thering gear 78 and theinput pinion gear 60 is established in the usual manner, the bearingretainers 148 and 150 can be locked in position.
As will be appreciated, many of the features shown in therear differential 28 of FIGS. 2 and 3 are also utilized in the interaxle front differential 22 illustrated in FIGS. 5-7. For example, in FIGS. 5 and 6, adifferential mechanism 178 used to drive thewheels 54, the bearing structure utilized to support thedifferential mechanism 178, and the method of installing the differential mechanism within the associated housing can all be similar to that of therear differential 28. Thus, to simplify the description, components in the front differential 22 similar to those in the rear differential 28 will be identified by similar, but primed, reference numerals such as pinion gear 60'.
As shown in FIG. 5, the interaxle front differential 22 includes amain housing 180 which defines aflange section 182 having a plurality of bolt holes 184 formed therein for bolting thehousing 180 onto thehousing 42. Theinput yoke 30 is fastened to aninput shaft 186 by a nut andwasher assembly 188 applied to a threadedstud 190 integral with theshaft 186. Theinput yoke 30 is rotationally interlocked to theinput shaft 186 bymating splines 192. An input cap 194 (also shown in FIG. 7) is bolted to thehousing 180 bybolts 196. Theinput cap 194 is provided with an aperture into which aninner collar 200 of theyoke 30 extends. An annular seal means 202 is positioned between thecap 194 and theyoke collar 200. Also, thecap 194 includes an annular recessed mounting surface 204 for receiving atapered roller bearing 206 which rotatably supports the front end of theshaft 186.
Theshaft 186 includes an intermediate splined portion 214 which carries agear 216 which, if desired, can be used to drive an oil pump (not shown) attached to an external portion of thehousing 180. Thegear 216 is preferably installed next to asnap ring 218 which serves to locate thegear 216. A dogclutch ring 220 having internal splines engageable with the splined portion 214 is moveable axially along the splined portion 214 by a shifting fork 222 (also shown in FIG. 7) which engages an annular groove formed in theclutch ring 220. Theshift fork 222 can be actuated in a conventional fashion such as by a solenoid, for example.
As shown in FIG. 5, a disk-shapedinput side gear 230, which is one component of an interaxle differential 231, is freely rotatably mounted on theshaft 186. Thegear 230 has a first frontplanar surface 232, having a plurality of circumferentially spaced, inset dog clutch teeth 234 for selective engagement with external teeth 235 on theclutch ring 220. Thegear 230 has a second rearplanar surface 236 opposite thesurface 232, and which defines a plurality of insetside gear teeth 238 for engagement with a set of four differential pinion gears 240 (only two shown in FIG. 5). It will be appreciated that both the dog clutch teeth 234 and theside gear teeth 238 are formed inwardly of their respectiveplanar surfaces 232 and 236. It has been found that such a construction reduces the overall axial length of the interaxle differential mechanism as compared with prior art assemblies.
The pinion gears 240 are rotatably mounted on apinion gear carrier 242, which is fastened to theshaft 186 at a second mating rear splined portion 244. Theshaft 186 has abearing end 246 which is received in an aperture in aneck portion 248 of aside gear 250. Theside gear 250 is rotatably mounted in thehousing 180 by abearing 252, and engages the teeth of the pinion gears 240. Theside gear 250 and an output shaft shown as anoutput shaft 254 are non-rotatably interconnected through theneck portion 248 bymating splines 256.
The rear end of theshaft 254 is mounted to theoutput yoke 34 bymating splines 255, and is secured thereto by means of anut 256 fastened to a threadedstud 258 integral with theshaft 254. Theyoke 34 includes acollar portion 262, adjacent themating spline section 255, which passes through an annular seal means 264 into arear housing 266. Therear housing portion 266 is fastened to thedifferential housing 42. The rear end of theshaft 254 is rotatably supported within thehousing 266 by opposed taperedroller bearings 268 and 270.
The disk-shapedgear 230 also carries radialperipheral gear teeth 280 for engagement withteeth 282 of an output gear shown as thegear 284. Thegear 284 is non-rotatably affixed to an output shaft shown as thepinion shaft 286 bymating splines 288. The rearmost end of theshaft 286 carries the pinion gear 60', corresponding to thepinion gear 60 of FIGS. 2 and 3. A taperedroller bearing 290 rotatably supports the rear end of theshaft 286 relative to thehousing 180. Aspacer ring 298 is interposed between the inner race of thebearing 290 and thegear 284. Asecond spacer 300 is interposed between thegear 284 and an inner race of a taperedroller bearing 302 which rotatably supports the front end of theshaft 286. Thepinion shaft 286 is pre-loaded by means of anut 310 fastened to a threadedstud 312 integral with theshaft 286. Thenut 310 presses awasher 314 against the inner race of thebearing 302. This adjustment may be made after initial assembly and before the installation of acover 315. Thecover 315 is mounted bybolts 316 to thehousing 180. A plan view of thecover 315 is best seen in FIG. 7.
Thus, as best illustrated in FIG. 5, when thedrive shaft 24 is rotated, rotating theinput yoke 30, thepinion carrier 242 is rotated. This causes the interaxledifferential mechanism 231 to divide the power provided by thedrive shaft 24 between theside gear 250 and the disk shapedgear 230. Thegear 230 acts through thegear 284 and the pinion gear 60' to drive a ring gear 78' of a single axle differential mechanism, having a structure similar to the differential assembly of FIGS. 2 to 4. The power applied to theside gear 250 passes through theshaft 254 to theoutput yoke 34, which drives theintermediate drive shaft 26. Theintermediate drive shaft 26 drives theinput yoke 38 of the single rear differential shown in FIGS. 2 and 3, so that each of the four wheel assemblies of thewheel assemblies 54 and 56 may rotate at different speeds as required by cornering and uneven road conditions.
However, when the teeth 235 of the dogclutch ring 220 are slid into engagement with the teeth 234 of the disk-shapedgear 230, thegear 230 becomes locked to theshaft 186. With thepinion carrier 242 also non-rotatable with respect to theshaft 186, the interaxledifferential mechanism 231 forms a solid connection between tneinput yoke 30 and theoutput yoke 34, so that the two wheel assembly pairs 54 and 56 cannot operate at different average speeds. This is advantageous when the traction of thewheel assemblies 54 and 56 to the ground or supporting surface is marginal.
In operation of an interaxle differential assembly, when the associated vehicle is moving, the rotation of the ring gear 78' causes lubricating oil (not shown) in amain oil sump 318 to be flung towards the area of the interaxledifferential mechanism 231 through an opening 317 (shown in FIG. 6), thus lubricating the interaxle differential and also lubricating all bearings that are above the normal level of lubricating oil in themain oil sump 318. However, as is conventional, and as illustrated, rolling elements are not interposed between thepinion gear carrier 242 and the pinion gears 240 or between the input shaft and the interaxle differential input side gear, so that these elements may move with rubbing friction for a very brief period of time when the associated vehicle first begins to move after a lengthly stopped period. Because of this, these components are considered wear parts which must be replaced, although at quite infrequent intervals. In response to this problem, interaxle differential assemblies have been provided with separate lubricating pumps externally mounted to provide start-up lubrication. Although such a lubricating pump may be used with the interaxle differential of the present invention, it is not necessary because of the provision of a simple, yet effective, secondary lubricant sump which will now be discussed.
Referring to FIG. 5, it can be seen that thehousing 180 includes an internal support portion 319 which extends below the interaxledifferential mechanism 231 and is used to support the outer races of thebearings 252 and 290. The portion 319 also functions to partially enclose the lower half of the interaxledifferential mechanism 231 in thearea 320. However, as will be appreciated, without the present invention, lubricating oil which normally enters thearea 320 by means of the ring gear 78' would drain back into themain sump 318.
The function of a separate secondary lubricant sump for the interaxle differential 231 may be accomplished by providing anapertured cup member 322 partially enclosing thepinion carrier 242. Thecup member 322 has a centrally locatedaperture 323 formed therein through which theshaft 186 extends, and an outerannular lip 324 secured to the internal support portion 319. Theaperture 323 also provides clearance for the teeth of the pinion gears 240 and theteeth 238 of the disk-shapedgear 230. The secondary lubricant sump formed by the addition of thisapertured cup member 322 is sealed by an annular lip seal means 326 disposed in an annular groove in the rear face of the disk-shapedinput gear 230, and in sealing contact with the front surface of theapertured cup member 322. Thus, when operation of the vehicle causes the rotation of the ring gear 78' to throw lubricating fluid into the area of the interaxle differential, it will be trapped in thelubricant sump 320 defined by the internal support portion 319 of thehousing 180, theapertured cup member 322, the lip seal 326, and the disk-shapedgear 230.
Also, in FIG. 5, an O-ring 328 is positioned within an annular groove formed in thehousing 180 for sealingly contacting theneck portion 248 of theside gear 250. In the embodiment shown in FIG. 5, the level of oil in thesecondary lubricant sump 320 will be limited by thelowermost portion 230 of theopening 317 through which the oil is flung by thering gear 78. Thus, with the present invention, start-up lubrication will be provided to the interaxle differential 231 the next time the associated vehicle is moved.
To further assist in the lubrication of the interaxle differential, the disk-shapedside gear 230 is provided with a plurality of circumferentially spacedoil passageways 332 which extend from theside gear teeth 238 to the inner bore provided in thegear 230. Similarly, theside gear 250 is provided with oil passageways 334 which extend from the respective side gear teeth to the associated inner bore area. It has been found that, when operating, the rotating pinion gears 240 produce a pumping action which forces oil through thepassageways 332 and 334 and into the inner bore areas of thegears 230 and 250. Thus, additional lubricating oil is provided between the inner bore surfaces of thegears 230 and 250 and the corresponding contacting outer surface portions of theshaft 186.
It will be appreciated that numerous modifications and variations of the disclosed embodiments of the invention may be easily made by one skilled in the art without departing from the spirit and scope of the claimed invention.